Gas gas MOTOR FSE 450 2004 / 2005 WORKSHOP MANUAL

MANUAL DE TALLER /

WORKSHOP MANUAL

MOTOR FSE 450

2004 / 2005

WORKSHOP MANUAL

ENGINE FSE 450

2004 / 2005

ENGLISH

Contents

Technical specifications................................................................4

Uninstalling and installing the engine in the chassis..................5

Engine dismounting................................................................15

Engine mounting...................................................................33

Replacement of the standard clutch with the ADLER

clutch APTC....................................................................................53

Inspection and maintenance

of the engine components.......................................................59

Periodic maintenance...............................................................91

MODEL FSE 400 / 450 ENGINE

Displacement in cubic centimetres

399 cc / 443 cc

Type

4 stroke DOHC 4 valves

No. of Cylinders

One

Cooling System

Water Cooled

Bore and stroke

90 x 62,6 mm / 95 x 62,6 mm

Injection

Fuel injection electronic system Magneti Marelli

Ignition

Integrated in fuel injection electronic system

Clutch

Oil bath, multi-disk hydraulic action

Gear Box

6 speed

CHASSIS

Frame Type

DELTABOX, semi double cradle chassis made from rectangular Cromoly tubes. Aluminium swing arm

Front Suspension

Inverted Marzocchi

Diameter 45 mm Run 295 mm

Inverted Öhlins

Diameter 48 mm Run 295 mm

Rear Suspension

Progressive system with Öhlins shock absorber Run 320 mm

Front brake

Disk of 260 mm Nissin Pump and simple / double Nissin calliper

Rear brake

Disk of 220 mm Nissin Pump and simple / double Nissin calliper

Wheels

Rims D.I.D. Type U with tyres Michelin Comp3

Technical Specifications

DIMENSIONS

Wheel base

1.475 mm

Seat Height

940 mm

Minimum ground clearance

340 mm

Fuel Tank Capacity

7.2 litres

Technical

Specifications

Un-installing and installaing the engine in the chassis

Un-installing the engine

Un-installing the engine in the chassis

Before dismounting the engine from the frame, wash it with a steam washer. The dismounting sequence is explained in the following steps.

Dismount the seat and the frame covers.

Empty the engine oil.

Remove the engine plate.

Empty the chassis (A) oil tank. Empty the coolant of the engine (B).

Disconnect the wire (-) of the battery (C) and the engine earth connection (D).

Un-installing the engine

Disconnect the alternator clamp (E) and the phonic wheel sensor wire.

Disconnect the spark plug pipe (F), the engine oil vaporiser tube (G), the engine oil resevoir vent hose (H).

Loosen the cylinder head injector tubing clamp (l).

Disconnect the starter motor connection wire (J). Dismount the starter motor removing the screws (K).

Un-installing the engine

Dismount the water tube (L).

Remove the pedal starter lever (M).

Remove the exhaust collector (N).

Disconnect the 2 radiator tubes.

Un-installing the engine

Disconnect the engine oil tube (O) in the chassis tank.

Remove the gearshift lever (P).

Remove the engine pinion protector (Q).

Remove the clutch cap (R). De-tense the chain.

Remove the output pinion clip (S).

Un-installing the engine

Remove the Engine pinion (T).

NOTE: Observe which is the placement direction of the said pinion.

Remove the carved bolts and the brake pedal.

Remove the motor from the frame.

Un-installing the engine

Installation of the engine in the chassis

Mount the engine in inverse order to de-installation

Fix the screws and engine fixing nuts.

NOTE: In this phase, temporarily tighten the nuts. The engine fixing nuts are self-locking. Once removed they lose their self-locking capability and are useless.

PRECAUTION Replace the engine fixing nuts with new ones.

Hold the screw heads with a spanner and tighten the engine fixing screws with the specified torque.

Element Nm Kgm A 66 6,6 B 66 6,6 C 66 6,6

Length of the screws

(A): 108 mm (B): 110 mm (D): 103 mm

Fix the brake pedal screw with the specified torque.

Brake pedal screw: 29 Nm (2,9 Kg)

PRECAUTION Replace the carved bolts with new ones.

Un-installing the engine

Mount the engine pinion.

NOTE: Observe which is the placement direction before the said pinion, to be able to achieve the same direction of wear.

Place the engine pinion clip.

Connect the chassis tank tube.

Fix the exhaust collector screw (1), with the specified

torque.

NOTE: Apply component NURAL 29 in the exhaust system joints.

Un-installing the engine

NOTE: Apply LOCTITE 243 to the pedal starter lever screw.

Fill 1.2 L of an engine oil classified SF or SG through the API service and with a degree of viscosity SAE 10W-40 through the oil fill mouth in the frame (A) and check the level.

DATA Engine oil capacity Change of oil: 1 L Changing the oil and filter: 1.2 L Engine general inspection: 1.2 L

3 min

Start the engine and leave it running some three minutes at idle.

Stop the engine and wait three minutes; immediately check the oil level via the rod.

Minimum level

Maximum level

Un-installing the engine

Dismounting the engine

Loosen the 3 screws that hold the starter clutch cover.

One of the 3 also holds the alternator cover.

Remove the starter clutch cover.

Extract the starter clutch.

Loosen the 2 screws that hold the starter motor.

Extract the starter motor.

NOTE: The 2005 starter motor turns in the opposite direction to that of 2004.

Dismounting the engine

Loosen the 7 retaining screws that hold the alternator cover.

One of them is located in the starter clutch cavity.

Remove the alternator cover.

Loosen the 2 screws that hold the position sensor (Pick-Up) (A).

Remove the de-multiplier pinion (B).

Loosen and extract the spark plug.

Dismounting the engine

Loosen the crankshaft nut.

NOTE: The nut loosens towards the right.

Turn the alternator rotor until placing the 7th tooth (A) of the phonic wheel in the center of the position sensor (Pick-Up) hole.

Loosen the 3 screws that hold the cylinder head cover.

Remove the cylinder head cover.

With the help of the extractor (Ref: MFS400134045), remove the alternator rotor.

Dismounting the engine

Loosen the 3 screws that hold the oil extractor pump.

Remove the oil extractor pump cover.

Remove the oil extractor pump.

Loosen the 2 screws that hold the distributor chain tensor.

Remove the distributor chain tensor.

Dismounting the engine

Remove the oil distributor.

Loosen the 2 lateral screws that hold the cylinder head to the cylinder.

Loosen the rear screw that holds the cylinder to the cylinder head.

Loosen the front screw that holds the cylinder to the cylinder head.

Loosen the 8 screws of the covers of the 2 camshafts and the distribution chain skate.

Dismounting the engine

Remove the distributor chain upper skate.

Remove the intake camshaft cover.

Remove the exhaust camshaft cover.

Remove the intake camshaft.

Remove the exhaust camshaft.

Dismounting the engine

Loosen and remove cylinder head lateral screw.

Loosen the 4 locking screws that hold the cylinder head.

Remove the 4 screws.

Remove the cylinder head.

Remove the cylinder head gasket.

Dismounting the engine

Remove the distributor chain front skate.

Loosen the 2 screws that hold the cylinder to the engine housing.

Hold the distributor chain and remove the cylinder.

Remove one of the clips that hold the piston casing and push to remove it.

Remove the cylinder gasket.

Dismounting the engine

Loosen the 5 screws that hold the cover of the clutch disks.

Remove the cover of the clutch disks.

Screw the centering tools into place (supplied together with the tools for the motorbike) and tighten them to 10 Nm.

NOTE: This operation is mandatory to ensure the correct dismounting of the clutch.

Remove the 3 screws, the 3 washers and the 3 springs that hold the clutch unit.

Remove the clutch press cover.

Dismounting the engine

Remove the clutch pusher.

Open the washer lug.

Loosen the fixing bolt, blocking the clutch bell turn with the tool Ref. MFS4504500220.

Remove the clutch unit.

Loosen the 3 screws that hold the oil filter cover.

Dismounting the engine

Remove the oil filter cover.

Remove the oil filter and the spring.

Loosen the screws that hold the clutch casing.

Remove the clutch casing.

Remove the clutch bell.

Dismounting the engine

Loosen the screw that holds the distributor chain tensor skate and remove it.

Remove the gear selector axle.

Remove the gear pedal axle spring.

Remove the gear pedal axle unit.

Remove the starter intermediate pinion clip.

Dismounting the engine

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Gas gas MOTOR FSE 450 2004 / 2005 WORKSHOP MANUAL

Specifications and Main Features

Frequently Asked Questions

User Manual